Experimental and Numerical Study of Thermal Residual Stresses on Multimaterial Adherends in Single-Lap Joints

The presence of residual stresses in composite materials can significantly affect material performance, especially when integrated in bonded joints. These stresses, often generated during the cure process, can cause cracking and distortion of the material, and are caused by differences in the coefficients of thermal expansion or cure shrinkage. In the current research, multimaterial adherends combining carbon-fibre-reinforced polymer (CFRP) and aluminium in a single-lap joint (SLJ) configuration are analysed, allowing us to understand the effect of the thermal residual stresses, developed during the curing process, in the overall performance of the joints. A numerical model resorting to a finite element analysis (FEA) is developed to assess and predict the behaviour of the joints. The use of FML (fibre metal laminates) was found to significantly improve the strength of the joints, as well as the failure mode. The proposed geometry performed similarly to the comparable FML geometry, in addition to a decrease in the joint weight.